Garments Having Auxetic Foam Layers

ABSTRACT

A garment is provided that has a support region and a foam pad at the region. The foam pads has at least one auxetic foam layer. A garment is also provided that includes at least one auxetic foam layer.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 11/498,032, filed Aug. 2, 2006, still pending.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure is related to garments. More particularly, the present disclosure is related to garments having at least one auxetic foam layer.

2. Description of Related Art

Many garments such as, but not limited to, intimate apparel garments including brassieres, camisoles, bathing suits, pantyhose, leotards, and others are known. Many garments include one or more support and/or shaping regions (“support regions”). For example, brassieres typically include a pair of breast cups for supporting and/or shaping the breasts of the wearer. Some prior art breast cups included a molded foam member that is sewn or otherwise secured to the brassiere in the area of the breast cups.

Unfortunately, typical molded foam members in the breast cups have not proven effective for use as sports brassieres. Namely, such molded foam members alone do not provide sufficient support of the breasts when exposed to the conditions present during running, jogging, jumping, and other sports related movements. Thus, typical sports brassieres use high elastic knit structures, in lieu of or in addition to the molded foam members, to provide sufficient support, which can lead to discomfort during use.

Moreover, brassieres having typical molded foam members in the breast cups can provide limited support to the user during stretching movements common in everyday life.

Accordingly, there is a continuing need for garments that overcome, alleviate, and/or mitigate one or more of the above deleterious effects of the prior art.

BRIEF SUMMARY OF THE INVENTION

It is an object of the present disclosure to provide a garment having one or more auxetic foam layers.

These and other objects and advantages of the present disclosure are provided by a garment that has a support region and a foam pad at the support region.

The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a front perspective view of an exemplary embodiment of a garment having a foam pad according to the present disclosure;

FIG. 2 is an exploded view of the foam pad of FIG. 1;

FIG. 3 illustrates a schematic view of a structure of an auxetic foam layer of the foam pad of FIG. 2 when unstressed; and

FIG. 4 illustrates a schematic view of the polymer structure of FIG. 3 when placed in tension.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the figures and in particular to FIGS. 1 and 2, an exemplary embodiment of an intimate apparel garment according to the present disclosure is generally illustrated by reference numeral 10. Garment 10 includes one or more support regions 12 (two shown) each having a foam pad 14 secured thereto. For purposes of clarity, garment 10 is illustrated as a brassiere and support region 12 is illustrated as breast cup regions of the brassiere.

Foam pad 14 can be secured to garment 10 in any known manner. For example, foam pad 14 can be secured to garment 10 by a seam, an adhesive, and combinations thereof. In exemplary embodiments, the seam can be a sewn seam and/or a welded seam.

Advantageously, foam pad 14 includes at least one auxetic foam layer 16 (only one shown). In one embodiment, foam pad 14 can also include one or more conventional or non-auxetic foam layers 18 (only one shown). Auxetic foam layer 16 and/or conventional foam layers 18 can be open-cell foam or closed-cell foam. Auxetic foam layer 16 can be a polymer auxetic foam layer, a metallic auxetic foam layer, or any combinations thereof.

As used herein, the term “auxetic foam” means a foam structure that exhibits a negative Poisson's ratio. Specifically, auxetic foam layer as used herein is a foam layer that expands in one or more directions when placed under tension. Thus, auxetic foam can become fatter in one or more directions when stretched.

Such auxetic behavior is in contrast to ordinary or conventional foam layers that become substantially thinner when stretched. Thus, traditional or prior art foam pads having only conventional foam layers get smaller during body movements, which is a time when the body needs additional support. Advantageously, it has been determined that garment 10 having foam pad 14 including at least one auxetic foam layer 16 provides support and shaping during times that the foam pad is placed in tension, such as when the wearer is stretching.

Further, auxetic foams, much like typical foams, contract in one or more directions when placed under compression so that the foam becomes thinner in one or more directions when compressed.

Foam pad 14 can also include one or more fabric layers 20 covering auxetic foam layer 16 and, when present, conventional foam layer 18. For example, foam pad 14 can include a fabric layer 20 on one or both sides of auxetic foam layer 16, when only auxetic foam layer 16 is present. Additionally, foam pad 14 can include a fabric layer 20 on one side of auxetic foam layer 16 and/or conventional foam layer 18, when the conventional foam layer is present.

For purposes of clarity, foam pad 14 is illustrated having one auxetic foam layer 16 adjacent one conventional foam layer 18, the composite of which is sandwiched between two fabric layers 20. Of course, it is contemplated by the present disclosure for foam pad 14 to include a plurality of auxetic foam layers 16, a plurality of conventional foam layers 18, a plurality of fabric layers 20 on one or more sides of the foam pads, or any combinations thereof. It is contemplated by the present disclosure for fabric layer 20 to be part of garment 10, for example foam pad 14 can be sewn or otherwise joined directly to garment 10.

Referring now to FIGS. 3 and 4, an exemplary embodiment of a structure of auxetic foam layer 16 is shown schematically. Auxetic foam layer 16 includes a structure that unfolds or opens when placed under tension. In the illustrated embodiment, auxetic foam layer 16 is a bi-directional polymer structure that unfolds or opens when subjected to tension in a first direction 22 and/or a second direction 24.

Of course, it is contemplated for auxetic foam layer 16 to have any desired structure sufficient for the layer to open or unfold in at least one direction (e.g., uni-directional), in a number of directions (multi-directional), or all directions (e.g., omni-directional).

In addition, it is also contemplated for foam pad 14 to include a plurality of unidirectional auxetic foam layers 16, where the unidirectional auxetic foam layers are oriented with respect to one another so that the resultant foam pad can open or unfold in as many directions as desired.

Auxetic foam layer 16 can have a negative through-thickness Poisson's ratio and/or a negative in-plane Poisson's ratio.

A negative through-thickness Poisson's ratio leads to thickening of the foam when stretched. In embodiments where foam pad 14 includes both auxetic and conventional foam layers 16, 18, the magnitude of the through-thickness negative Poisson's ratio can be sufficient to, for example, maintain a constant thickness of foam pad 14 or to lead to an overall increase in thickness of the foam pad 14, when stretched. For a constant thickness foam pad 14, the magnitude of the negative through thickness Poisson's ratio of auxetic foam layer 16 should be substantially similar to the magnitude of the conventional foam layer 18. If equal thicknesses of auxetic and conventional foam layers 16, 18 are employed, then the auxetic foam layers' Poisson's ratio should be equal in magnitude but opposite in sign to that of the conventional foam (e.g., conventional foam layer having Poisson's ratio: 0.2 to 0.3, and auxetic foam layer having Poisson's ratio: −0.2 to −0.3) to maintain constant thickness of foam pad 14. If the auxetic foam layer 16 has a smaller thickness than the conventional foam layer 18, then the auxetic foam will require a larger magnitude of (negative) Poisson's ratio than that of the (positive Poisson's ratio) conventional foam. Preferably, auxetic foam layer 16 has a through-thickness negative Poisson's ratio of between about 0.0 to about −1.0 and any subranges therebetween.

A negative in-plane Poisson's ratio leads to increase in the area of foam pad 14 cup on stretching. Preferably, foam pad 14 has a negative in-plane Poisson's ratio sufficient to maintain the surface area and/or shape of the foam pad upon deformation. For example, foam pad 14 can have a negative in-plane Poisson's ratio in the range of about 0.0 to about −1.0 and any subranges therebetween. Preferably, foam pad 14 has a negative in-plane Poisson's ratio of about −0.8.

In some embodiments of the present disclosure, auxetic foam layer 16 can be configured to release of one or more chemical agents (not shown) when in the open or unfolded position shown in FIG. 4. The chemical agents can include agents such as, but not limited to, deodorants, perfumes, antiperspirants, medications, and others.

It should be recognized that it is contemplated by the present disclosure for foam pad 14 to find use in support regions 12 of garment 10 other than breast cup region such as, but not limited to, a strap region 26 (FIG. 1), chest band region 28 (FIG. 1), and a side wing panel 30, any other garment region where support and shaping are desired, and any combinations thereof.

It is also contemplated by the present disclosure for foam pad 14 to find use in garments 10 other than a brassiere. For example, foam pad 14 can find use in any intimate apparel garment including a camisole, a bathing suit, a leotard, a panty, or any other garment for females or males where support and shaping are desired.

Foam pad 14 can have any shape desired for support region 12. For example, when foam pad 14 is used as a breast cup, the foam pad can have a generally hemispherical shape. In some embodiments, auxetic foam layer 16, and when present conventional foam layer 18, are first formed as flat sheets then molded to the desired shape (i.e., a molded foam layer). In other embodiments, auxetic foam layer 16 can be cut or machined to the desired shape from a block of auxetic foam (i.e., a machined foam layer). In still other embodiments, a sheet of the auxetic foam layer 16 can be cut from a block of auxetic foam and then molded to the desired shape (i.e., a machined and molded foam layer).

Auxetic foam layer 16 having the negative in-plane Poisson's ratio can be produced by, for example, a triaxial compression and heat treatment process to produce a large isotropic auxetic foam block, from which a sheet (flat or curved) is then cut or machined.

It should also be recognized that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.

While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims 

1. A garment having at least one padded portion, the padded portion comprising: an auxetic foam layer having first and second surfaces; a non-auxetic foam layer adjacent the first surface of the auxetic foam layer; at least one fabric layer adjacent the second surface of the auxetic foam layer; and wherein the padded portion maintains at least a constant thickness when stretched in at least one direction.
 2. A garment having a padded portion, the padded portion comprising: an auxetic foam layer having a first surface; a fabric layer adjacent the first surface of the auxetic foam layer; and wherein the auxetic foam layer is selected from the group consisting of foam layers having a negative through-thickness Poisson's ratio, a negative in-plane Poisson's ratio, and combinations thereof.
 3. A garment having a padded portion, the padded portion comprising: an auxetic foam layer having a first surface; a fabric layer adjacent the first surface of the auxetic foam layer; and wherein the auxetic foam layer is selected from the group consisting of a polymer auxetic foam layer, a metallic auxetic foam layer, and combinations thereof. 